Transfer Case Front Oil Seal Replacement

Remove the filler plug and gasket.

Remove the drain plug and gasket to drain the transfer oil.

Install a new gasket to the drain plug, and then install the plug.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Remove the 4 bolts and lower transfer case protector.

Using a chisel and hammer, loosen the staked part of the lock nut.

Using SST to hold the companion flange, remove the lock nut.

SST

09330-00021

Using SST, remove the front output shaft companion flange sub-assembly.

SST

09950-40011(09951-04020,09952-04010,09953-04030,09954-04010,09955-04051,09957-04010,09958-04011)

Using a screwdriver and hammer, tap out the oil seal from the companion flange.

NOTICE:

Be careful not to damage the oil seal and companion flange contact surfaces.

Using SST, tap out the transfer case oil seal.

SST

09308-00010

NOTICE:

Be careful not to damage the oil seal and front case contact surface.

Coat the lip of a new oil seal with MP grease.

Using SST and a hammer, tap in the oil seal until its metal ring contacts the case.

SST

09649-17010
09950-70010(09951-07100)

Using SST and a hammer, tap in a new oil seal to the front output shaft companion flange sub-assembly.

SST

09950-60010(09951-00320)
09950-70010(09951-07100)

NOTICE:

Be careful not to damage the companion flange.

Apply gear oil to the connecting areas of the front output shaft companion flange sub-assembly and transfer driven sprocket.

Install the front output shaft companion flange sub-assembly to the transfer driven sprocket.

Using SST to hold the companion flange, install a new lock nut.

SST

09330-00021

Torque:

118 N*m{1203 kgf*cm, 87 ft.*lbf}

Using a chisel and hammer, stake the lock nut.

NOTICE:

1. Securely stake the shaft to the lock nut groove.
   
2. Be careful not to damage parts around the lock nut.
   
3. Do not apply excessive force to the shaft.
   

Install the protector with the 4 bolts.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Add transfer oil until the oil level is within 5 mm (0.196 in.) from the bottom of the transmission filler plug opening.

Install a new gasket to the filler plug, and then install the plug.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

NOTICE:

1. When adding transfer oil, make sure the vehicle is level.
   
2. An excessively large or small amount of oil may cause problems.
   
3. After adding oil, drive the vehicle and recheck the oil level.
   

Inspect for transfer oil leaks.